In the manufacturing industry, there are commonly the following misconceptions about high-speed milling:
1) A high-speed milling machine is just a milling machine equipped with a high-speed spindle
2) The higher the spindle speed, the faster the machining speed
3) High speed milling machines are only meant to replace traditional milling machines
4) A spindle of 20000 revolutions per minute is sufficient for the production of molds
5) High speed milling machines only increase the speed of axial servers
6) High speed milling machines can only machine electrodes
7）………
In fact, high-speed milling machines are a new process technology and application
To maximize the efficiency of high-speed cutting, it is necessary to closely coordinate each link. If any link is poorly coordinated, the efficiency of high-speed cutting cannot be fully utilized.
1) High speed tool holder and cutting tools
2) High speed spindle
3) High power XYZ axis
4) High speed CNC controller
5) High speed program strategy
1Basic situation during high-speed cutting
As the speed increases to a certain extent, the temperature and cutting force of the tool will gradually decrease. This phenomenon is used in high-speed milling technology.
（传统铣削状态）
（高速铣削状态）
Dispersion ratio of high-speed cutting heat source:
IIThe difference between high-speed milling and high-speed milling concept
The machining concepts of high-speed milling (HSM) and high-performance milling (HPM) are different. For example, the rough machining of hardened steel with a material hardness greater than 55HRC is illustrated in the following diagram.
Schematic diagram of HPM (left) and HSM (right) machining concepts
IIIApplication scope of high-speed milling
1) In order to match the spindle specifications, ensure machining stability and safety, the tool diameter should not exceed 16mm (HSK-E40).
2) Compared with traditional milling, the cutting removal rate of high-speed milling is relatively small, which is very suitable for small parts and mold processing applications.3) Can be applied to new processing applications such as thin film processing and microfabrication.4) It is a new concept processing method for soft or superhard materials.Example: Aluminum parts with a wall thickness of 0.5mm may not be produced without high-speed milling technology.
4The center of gravity in high-speed milling
1) High speed matching tool holder and cutting tool
Actually, it's not the machine cutting, it's the tool! Cutting tools are like the tires of a car, they are the only parts in the car that come into contact with the ground. Good and suitable tires are the key to victory in racing. The selection of cutting tools and processing conditions can be based on the information provided by the tool supplier, but users still need to adjust them according to the actual processing situation.Criteria for selecting cutting tools:1) Diameter (based on the geometric dimensions and accuracy of the workpiece)2) Types (rough machining, precision machining, slotting, 3D contouring, edge machining...)3) Shape (ball cutter, round nose cutter, multi blade milling cutter, etc.)4) Materials (high-speed steel, hard alloy, metal ceramics, diamond, cubic boron nitride CBN)5) Tool coating (TiN, TiCN, TiAlN...)6) Quality (radial runout, shape accuracy, dynamic balance, rigidity)In fact, the high-speed spindle is like the high-speed engine and high power inside an F1 car.The spindle can be roughly divided into two specifications:1）有轴承的=>High torque, currently capable of reaching a maximum speed of 54000 revolutions per minute.2）无轴承的（气体带动）=>低扭力，但转速非常快（>100krpm） 。High torque allows for cutting of larger materials, using larger tools and harder materials. High speed allows for faster cutting rates and achieves the effect of HSM.(3) High dynamic performance axesIn fact, the bed structure of the machine itself is like the chassis of a car, strong and safe in absorbing impacts and vibrations.Traditional hard rails can achieve better accuracy through adjustments on the machine, but they cannot achieve the high-speed machining that linear slides can achieve. The high-speed axes and sturdy bed structure, acceleration is the key factor. The high-speed axes reduce time waste, better cutting surfaces, and lower tool wear.(4) High speed milling controller CNCIn fact, the controller is like a driver, and its operational skills determine the outcome of the race car. It requires foresight, sensitivity, and quick responsiveness.(5) CAM machining strategy for high-speed millingIn fact, there are many paths that can lead from one point to the next, but all paths will have different effects on speed, surface, etc.
(Article source:OK智能制造）
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